Laminated pizza crust

ABSTRACT

A method for making a laminated pizza crust is disclosed herein. The pizza crust is produced by resting a formulated dough mixture, cutting the dough, rolling the dough into a sheet, extruding high-melt margarine on to the sheet and folding it over the margarine to form a fatted dough, stretching the fatted dough, piling the fatted dough onto itself to create several layers, stretching the dough a second time, piling and rolling the dough again, stretching the dough a final time to a predetermined thickness, puncturing the dough sheet, cutting the dough sheet into pre-determined pizza shapes, and finally baking the shapes. The baked crust can be topped with pizza ingredients and frozen. Upon reheating by the consumer in either the microwave or a conventional oven, the crust exhibits an improved texture, flakiness, and flavor.

BACKGROUND OF THE INVENTION

[0001] This invention relates to baked products and methods for makingthem. In particular, the invention relates to a method of making alaminated dough pizza crust. The laminated dough pizza crust of thepresent invention demonstrates improved palatability and stability whenheated in a microwave oven. Microwave ovens have provided a convenientmeans for heating a variety of frozen food products. Within thiscategory of frozen food products, frozen store-bought pizzas continue tobe a popular microwave-heatable item for consumers. These frozen pizzasoffer the convenience of being heatable in either a conventional oven ora microwave oven. The crusts for these pizzas have traditionally beenmade from a simple yeast-based dough, similar to that used for makingother bread products.

[0002] Frozen pizzas of the thin-crusted variety tend to be moregenerally favored if the crust has a crispy quality when cooked. Thesecharacteristics are easily accomplished in a conventional oven due tosuch an oven's direct surface heating and drying effects. In microwaveovens, however, excess moisture within the frozen crust often causes itto become soft and soggy. After prolonged exposure, the crust becomestough and unpalatable, with the crumb of the crust becoming rubbery andgummy. Reducing the amount of time the crust is exposed to microwaveenergy is usually not a possibility, because the pizza toppings must beheated to a proper serving temperature. By the time the toppings areadequately heated, the crust can already be unpalatable.

[0003] Various attempts have been made to overcome the problemsassociated with exposure of pizza crusts to microwave energy. Theseimprovements, however, have been only minimally successful. For example,dough formulas have been manipulated to make them homogeneously higherin shortening content and eggs. The inclusion of these additionalingredients slows the crust's absorption of microwave energy. Thesetypes of crusts do not have a pleasant taste or texture.

[0004] Other cures such as pre-cooking or pre-toasting have beenattempted to reduce the amount of moisture in the bread product and thusalleviate the problems caused when the product is exposed to microwaveenergy. However, the pre-cooking can degrade the taste and insteadcreate a dry, unappealing product. In the case of pizzas, the reductionof moisture in the pre-cooked crust becomes somewhat futile, because thelow moisture is counteracted by the addition of the pizza toppings, suchas tomato sauce, cheese, meats, and vegetables, all of whichre-contribute moisture to the crust. Moreover, the pre-toasting adds anadditional, expensive step to the entire pizza-making process.

[0005] Other methods for incorporating fat into pizza crusts have beendeveloped to improve the overall texture of the crust. One methodincludes incorporating flakes of shortening or fat into a homogenousdough. This crust is not specifically formulated for improvedmicrowavability, however, and such a crust does not adequately possessthe flaky texture of traditionally cooked thin-crusted pizzas.

[0006] Finally, some dough products for commercial foods such as piesand pastries are made using a laminated dough. A laminated doughtypically comprises thin layers of dough separated by either a layer offat or a layer of dough of a differing type. These laminated doughs havepreviously been used for puffed, highly risen pastries, which havelittle value for thin pizza crusts. Pizza crusts have also been madefrom a pressed laminated dough, although the advantages of using amultiple-layer dough tend to be lost during the steps of pressing orstamping the dough into discs. The pressing or stamping homogenizes muchof the layered structure.

SUMMARY OF THE INVENTION

[0007] It is therefore an object of the present invention to provide animproved frozen pizza crust that exhibits improved palatability andcrispness when exposed to microwave energy.

[0008] It is another object of the present invention to provide aformulation for an improved frozen pizza crust that exhibits improvedpalatability and crispness when exposed to microwave energy.

[0009] It is still another object of the present invention to provide asystem and method for making an improved frozen pizza crust thatexhibits improved palatability and crispness when exposed to microwaveenergy.

[0010] In one aspect of the present invention, a laminated pizza crustis produced by resting a formulated dough mixture, cutting the dough,rolling the dough into a sheet, extruding high-melt margarine on to thesheet and folding the dough over the margarine to form a fatted dough,stretching the fatted dough, piling the fatted dough onto itself tocreate several layers, stretching the dough a second time, piling androlling the dough again, stretching the dough a final time to apredetermined thickness, puncturing (docking) the dough sheet, cuttingthe dough sheet into pre-determined pizza shapes, and finally baking theshapes. The baked, laminated crusts can be topped with pizza ingredientsand frozen. Upon reheating by the consumer in either the microwave or aconventional oven, the crust exhibits an improved texture, flakiness,and flavor.

[0011] In another aspect of the present invention, an apparatus formaking pizza crusts includes a mixer for combining ingredients into adough, a roller for rolling the dough into a sheet, a folder forincorporating a layer of margarine into the sheet, a first stretcher forrolling the sheet, a first piler for layering the sheet to create afirst layered sheet, a second stretcher for rolling said first layeredsheet, a second piler for layering said first layered sheet to create asecond layered sheet, a third stretcher for rolling the second layeredsheet, cutters for dividing the second layered sheet into pieces, adocker for puncturing holes in the pieces, and at least one oven forbaking the pieces.

[0012] These and other features and advantages of the invention willbecome apparent upon the review of the following detailed description ofthe presently preferred embodiments of the invention, taken inconjunction with the appended figures.

DESCRIPTION OF THE DRAWINGS

[0013] The invention will be explained with reference to the drawings,in which:

[0014]FIG. 1 shows a high-level flowchart of the process for making thepizza crust of the present invention.

[0015]FIG. 2 shows a high-level flowchart of the process for producingthe dough mixture used in the present invention.

[0016]FIG. 3 shows a detailed flowchart of the sheeting and laminatingprocess used in the present invention.

DETAILED DESCRIPTION OF THE INVENTION AND THE PRESENTLY PREFERREDEMBODIMENT

[0017] In accordance with the present invention, the method for makingthe laminated pizza crust is shown generally in FIG. 1. Afteringredients for the dough are mixed (10-11), the dough is allowed torest a period of time (12). After this resting period, a sheeting andlaminating process (13) is performed on the rested dough to produce alayered sheet of dough and fat. When the laminated dough is of theproper thickness and comprises the desired number of layers, the doughis “docked” or punctured with holes to prevent ballooning of the dough,and cut into pizza-sized portions (14). Finally, the portions are bakedin ovens (15).

[0018] The following example shows the ingredients used in themanufacture of a pizza crust in accordance with the present invention.The crust mixture which is used in the preparation of the laminatedcrust includes approximately 60% by weight of a flour having a proteincontent of approximately 11%. 1.25% by weight of active dry yeast isalso added, along with 1.25% salt, 1.25% sugar, 1.25% uncolored, solidmargarine, and 32% water at a temperature between 50 and 60 degrees F.(all percentages are by weight of total dough). A dough conditioner isadded in a quantity of about 3% by weight. The conventional doughconditioner, preferably of the type manufactured by Microgold,stabilizes the mixture. A table summary of these ingredients in anexample batch (quantitized by weight of ingredients) is listed below.INGREDIENTS (example) Ingredient Pounds Flour - 11% Protein 100  Yeast -Dry Instant Active 2 Salt 2 Sugar 2 Margarine - Uncolored, Solid 2 Water52  Microgold Dough Conditioner 5 Hi-melt Margarine Roll-In % 10%

[0019] As shown in the flow diagram of FIG. 2, the ingredients are firstweighed (boxes 20-24 in the flow diagram), and the water, salt, sugar,yeast, and dough conditioner are mixed into a slurry (25). The waterused at step 20 is filtered water brought to the specified temperature.The slurry solution is then mixed and pumped to a use tank. The measuredflour, slurry, and margarine are then loaded (26-27) and mixed together(28). The mixing occurs at high speed for 2 to 3 minutes until apreferred target temperature of approximately 80-89 degrees F. isreached. After mixing, the dough is discharged onto an incline conveyorbelt and conveyed slowly for 45 minutes to 1 hour (29 in FIG. 2, 12 inFIG. 1). This “resting” or “airing” stage allows the yeast in the doughto activate and cause the dough to rise.

[0020] As shown in FIG. 1, following the resting period 12 the sheetingand laminating process 13 is performed on the dough. This process isillustrated by the flow diagram of FIG. 3. As shown in this figure,various cutting, rolling, and stretching operations are performed.

[0021] At box 40 in the flow diagram, a dough chunker divides the doughinto approximately 60 pound chunks in order to properly load a doughfeeder. At 41, the dough feeder receives the chunks of dough dumped intoa hopper. The conventional feeder uses a belt and cutting blade todeposit overlapping dough strips on a moving conveyor. The line ofstrips measures 35-50 mm thick and 480-570 mm wide. A roller is next runacross the overlapped dough to spread and even the distribution of thedough (42). The dough is then run through three sets of rollers togently work it into a thin sheet 6.5-8 mm thick (43).

[0022] High-melt margarine at a temperature between 65 and 71 degrees F.is extruded through a rectangular nozzle into a strip on the middlethird section of the dough sheet (44). The quantity of margarine addedby weight is equal to 10% of the total weight of the dough. The outerportions of the dough are then folded in overlapping thirds, thussandwiching the margarine in the middle of the dough and forming afatted dough.

[0023] The fatted dough is then stretched by a first stretcher at 45. Inthis operation, a series of rollers are rotated in a circular fashion.The dough passes underneath these rollers on three different conveyorsat a speed determined by a speed ratio setting. This setting incombination with the clearance between the rollers and the beltdetermines the final thickness of the dough after the rolling.

[0024] As shown in box 46, the fatted dough is “piled” by a first pilerto create a first series of layers. The piler travels back and forthdistributing the dough onto a conveyor belt situated at a 90 degreeangle from the direction of feed. The conveyor is thus loaded with asheet of dough having overlapping folds. The number of folds across thewidth of the dough sheet is multiplied by two to determine the number oflayers presently in the dough. The dough is then stretched by a secondstretcher at 47 into a fatted sheet, and piled by a second piler at 48to create a layered sheet having a thickness between 15 and 20 mm. Atthis point, the dough has its final sixteen-layer structure. The doughis then smoothed by a cross roller at 49.

[0025] Finally, at 50, a third stretcher rolls the dough to a finalthickness of 3-5 mm.

[0026] In order to determine the total number of layers the dough willeventually have, the number of layers present after the first piler ismultiplied by the number of layers present after the second piler. Forexample, if 4 layers are run after the first piler and 4 layers are runafter the second piler, the dough sheet will have a total of 16 layers.

[0027] After the final thickness is achieved, the dough sheet is cutinto six strips for rectangular pizza shapes. For other pizza shapes,the dough is left intact and lightly smoothed by a touch-up roller at51.

[0028] The dough is then “docked” or punctured at 52 to prevent thedough from expanding or “ballooning” in the oven. The puncturing isperformed by a roller with a large number of projecting pins to punch apattern of holes through the dough. At 53, the dough is put into itsfinal form by a cutter, which cuts the dough into pizza shapes. Theshapes are spaced evenly on a conveyor to promote even baking.

[0029] The cut dough shapes are then baked into crusts in gasimpingement ovens set between 475 and 550 degrees F. for 1.5-2.3minutes.

[0030] The dough conveying system used in the above-described process ispreferably a Model 710 manufactured by Stephan Machinery. The high-speeddough mixer is a Model TK160, also preferably manufactured by Stephan.The sheeting and laminating system preferably comprises componentsmanufactured by Rheon, and include the following components and modelnumbers: Surface Cleaner Model SV013, Sheet Folder Model FF111, StressFree Stretcher Model SM231, Flour Duster Model DF103, Dough Feeder ModelEX050, Underneath Conveyor Model PC502, CWC Cross Action Roller ModelM103, Fat Pump Model XC230, Roll-In Conveyor Model WC303, Sheet FolderModel FF101, Stress-Free Stretcher Model SM501, Pile-Up Table ModelPC011, Parallel Piler Model LM608, Pile-Up Table Model PC103, CrossRoller Model CM523, Flour Sweeper Model FV376, Stress-Free StretcherModel SM318, Circular Cutter Model OK833, Spacing Conveyor Model 2C672,Press Roller Model MR308, Single Rotary Cutter Frame Model RK013,Synchronized Conveyor Model MC013, and Guillotine Cutter Model GK013.The various ranges settings for these devices are shown in the tablebelow. PREFERRED RANGES AND SETTINGS FOR EQUIPMENT Low High Mixer MixTime (seconds) 100 180 Dough Chunker Intervals per minute 2 5 DoughFeeder Flour Setting # 1 (Beginning of Line) 10 30 Dough Intervals 230280 Flour Setting # 2 (Before Cross Roller) 10 30 Cross Roller Gage (mm)15 30 Action Roller Flour Setting # 3A (Top of Action 0.5 1.5 Roller)Flour Setting # 3B (Bottom of action 10 30 Roller) Roller Gage (mm) 4 7Set Dough Width (mm) 650 725 Output Belt Speed (m/min) 1.00 2.75 StretchRatio 2 4 Roll-In Belt Speed (m/min) 1.0 2.8 Screw Speed (rpm) 0.2 0.4Stretcher # 1 Flour Setting # 4A (Top of 20 35 Stretcher # 1) FlourSetting # 4B (Bottom of 10 30 Stretcher # 1) No. 1 Belt Speed/InclineAngle 1.0/15 deg. 2.75/40 deg. Speed Ratio 2.5 4.5 Roller Clearance (mm)0.8 2.0 Number of layers after Piler # 1 4 6 Folding Width (mm) 25/2540/40 Piler Belt Speed 300 700 Flour Setting # 5 (After Piler # 1) 10 20Stretcher # 2 Flour Setting # 6A (Top of 10 40 Stretcher # 1) FlourSetting # 6B (Bottom of 15 35 Stretcher # 1) Gage (mm) 1 3 Speed Ratio2.0 6.0 Input Thickness (mm) 15 25 Belt # 1 Speed (m/min) 1 3 Number oflayers after Piler # 2 4 6 Folding Width (mm) 650 700 Piler Belt Speed 412 Flour Setting # 7 1 3 Flour Setting # 8 (After Piler # 2) 0.8 2Stretcher # 3 Flour Setting # 9A (Top of 1 2.5 Stretcher # 3) FlourSetting # 9B (Bottom of 10 50 Stretcher # 3) Belt # 1 Speed (m/min) 0.52.5 Speed Ratio 2 5 Crank Clearance (mm) 1 5 Guillotine Cutter (forrectangular shapes) Cut Length (mm) 150 170 Gas Impingement Oven BakeTime (minutes) 1.5 2.3 Oven # 1 Temp (deg. F.) 500 550 Oven # 1 Fan (%of maximum) 40 60 Oven # 1 Height (inches) 1.5 3.5 Oven # 2 Temp (deg.F.) 475 525 Oven # 2 Fan (% of maximum) 50 80 Oven # 2 Height (inches)1.5 4.5 Baffles (Top/Bottom) 50/50 80/20

[0031] The preferred parameters for various dough dimensions andtemperatures are summarized below. These ranges are useful when theprocess of the present invention is performed on alternative equipment.The present invention is not limited to these parameters, although thoselisted have been found to be optimal for the equipment used. PREFERREDMEASUREMENT PARAMETERS Low High Room Temperature (deg. F.) 60 70 FormulaWater Temperature (deg. F.) 50 65 Yeast Solution Temperature (deg. F.)50 65 Dough Temperature after mix (deg. F.) 80 F. 89 F. Dough Widthafter feeder (W1 - mm) 480 570 Dough Thickness (T1 - mm) 35 50 DoughTemperature (deg. F.) 75 F. 85 F. Dough Width before butter roll-in(W2 - mm) 650 800 Dough Thickness before butter roll-in (T2 - mm) 6.5 8Roll-In Temperature (deg. F.) 65 F. 71 F. Dough Width after butterroll-in (W3 - mm) 280 320 Dough Thickness after butter roll-in (T3 - mm)20 30 Dough Width after stretcher # 1 (W4 - mm) 300 400 Dough Widthafter 1st Piler (W5 - mm) 300 350 Dough Thickness after 1st Piler (T5 -mm) 12 25 Dough Width after stretcher # 2 (W6 - mm) 250 350 Dough Widthafter 2nd Piler (W7 - mm) 600 700 Dough Thickness after 2nd Piler (17 -mm) 15 20 Dough Width after stretcher # 3 (W8 - mm) 600 700 Final DoughThickness (T8 - mm) 3 5 Cut Width (W9 - mm)(for rectangular shapes) 110120 Cut Length (L9 - mm)(for rectangular 148 160 shapes)

[0032] After the crusts are baked, they are cooled for a period of timebefore traditional pizza toppings are applied.

[0033] The various stretching and rolling procedures result in a unique16-layer laminated pizza crust with excellent taste and texture. Thecrusts are crispy and flaky, and are able to withstand topping,freezing, and microwaving without any significant degradation in thesequalities.

[0034] Of course, it should be understood that a wide range of changesand modifications can be made to the embodiment of the method describedabove. For example, variations in the ingredients, temperatureparameters, layering steps, or other parameters may be applied whileremaining within the contemplated scope of the invention. It istherefore intended that the foregoing detailed description be regardedas illustrative rather than limiting and that it be understood that itis the following claims, including all equivalents, which are intendedto define the scope of this invention.

What is claimed is:
 1. A method for making a pizza crust from a dough,said method comprising: resting said dough; cutting said dough; rollingsaid dough into a sheet; extruding margarine on to said sheet; foldingsaid sheet over said margarine to form a fatted dough; stretching saidfatted dough; piling said fatted dough; stretching said fatted doughinto a sheet; piling said fatted sheet; rolling said fatted sheet;stretching said fatted sheet to a predetermined thickness; puncturingsaid fatted sheet; cutting said fatted sheet into pieces; and bakingsaid pieces.
 2. The method as recited in claim 1 further comprising thestep of spacing apart said pieces before baking.
 3. The method asrecited in claim 1 wherein said resting step further comprises airingsaid dough at least 45 minutes.
 4. The method as recited in claim 1wherein said predetermined thickness further comprises between 3 and 5millimeters.
 5. The method as recited in claim 1 wherein said margarinefurther comprises a margarine having a melting temperature of at least65 degrees F.
 6. The method as recited in claim 1 wherein said doughfurther comprises: 60% flour; 1.25% yeast; 1.25% salt; 1.25% sugar;1.25% margarine; and 32% water.
 7. A method for making a pizza havingtopping ingredients, said method comprising: mixing a dough; restingsaid dough; cutting said dough; rolling said dough into a sheet;extruding margarine on to said sheet; folding said sheet over saidmargarine to form a fatted dough; stretching said fatted dough; pilingsaid fatted dough; stretching said fatted dough into a fatted sheet;piling said fatted sheet into 16 layers; rolling said fatted sheet;stretching said fatted sheet to a predetermined thickness; puncturingsaid fatted sheet; cutting said fatted sheet into dough pieces; bakingsaid dough pieces; allowing said dough pieces to cool; and applying saidtopping ingredients to said baked dough pieces.
 8. An apparatus formaking a plurality of pizza crusts, said apparatus comprising: a mixerfor combining ingredients into a dough; a roller for rolling said doughinto a sheet; a folder for incorporating a layer of margarine into saidsheet; a first stretcher for rolling said sheet; a first piler forlayering said sheet to create a first layered sheet; a second stretcherfor rolling said first layered sheet; a second piler for layering saidfirst layered sheet to create a second layered sheet; a third stretcherfor rolling said second layered sheet; cutters for dividing said secondlayered sheet into pieces; a docker for puncturing holes in said pieces;and at least one oven for baking said pieces.